HD downcoverting too small into NTSC

I've a 4:3 NTSC program that I upconverted to 1080i (it is full frame top to bottom w/blank image left and right). I then color corrected and edited it.
I cannot seem to get it back to a full frame 4:3 down covert out of the Kona SDI outputs. I tried al the options on the conversion tab (amorphic, crop and letter box) of the Kona 3 control Panel Format menu and none make a difference. It seems to play out at around 550 by 300 pixels in NTSC. I tried both SDI outputs. Any thoughts?